good evening 'all!
Thought I would share my 750 resurrection project.
Co-worker bought it as a box of parts, intending to rebuild it himself, but quickly realized how far in over his head he was. I acquired the bits and pieces for the outstanding price of $600.
Been working on this for almost 2 years now in whatever spare time I can scrounge up, which some months isn't much. :crying:
I have it completely re-assembled.
Fairings have been repaired and re-painted.
I fabricated a new windscreen from some material I found at work, and painted it to match the bike. Thinking I might cut it down further for a more interesting look, but still on the fence.
I designed a sequential LED circuit for the tail/blinkers. Still working out the details as far as mounting and such, but the end result will have the blinkers circling around each tail pod. Wanted to get the bodywork done before I got too crazy with the minor detailing. :smile:
I had to fabricate a new shifter mounting bracket as the original was damaged pretty bad.
Still need to replace the shift lever itself. Tis functional, but a little awkward as it stands.
The stator cover was cracked pretty bad, so replaced with a used one from our local salvage yard.
I re-covered the front seat because the original was in pretty sad shape. The back seat is better, but I think I will re-cover that as well, just so they match. :smile:
So... finally... I had it together enough to test! Fired up immediately, ran great except for the classic tensioner rattle. Rebuilt the tensioner and verified the timing. Now it runs great, sounds amazing. Toured my neighborhood with it a little, checking the ride, etc. Loving it. :grin2:
Then... went to start it again a couple days later and... nothing... :frown2:
Yep... the classic battery not charging syndrome...
Talked with the guy I bought it from and was informed that it had that problem before he bought it too. The previous owner replaced the stator and RR because it had the usual burned stator and fried connector.
The RR passes the meter tests, and the stator passes the ohm tests. Running the tests, the stator does not put out the correct AC voltage, in spite of looking brand new. Even the zip ties are still bright white!
At 5000 RPM, I get 34 volts on each set. Odd that all three are low, right? I usually see one set that is obviously bad when they fail.
Upon inspecting the rotor/flywheel, a couple of the magnet tabs are cracked (even tho primary magnets are layered behind the sleeve), and there is a noticeable gouge in the surface. Possibly from a previous crash? (the title does show prior salvage)
So... replaced the flywheel and still testing bad. :crying:
Since the original gentleman thought the bike was a 2000, I started thinking maybe he put the wrong parts in initially. There aren't any part numbers on the stator, but the micrometer measurements match what *should* be installed on a 99.
But the numbers are still no good. Next step will be to replace the stator with a known good one that is correct for this bike. That will have to wait for another paycheck or two though.
:gaah
Soooo close!! Getting antcy to get this thing on the road!
So all that remains is a set of mirrors and this charging issue resolved!!
Will update when I get the new parts installed!
-Troy
Thought I would share my 750 resurrection project.
Co-worker bought it as a box of parts, intending to rebuild it himself, but quickly realized how far in over his head he was. I acquired the bits and pieces for the outstanding price of $600.
Been working on this for almost 2 years now in whatever spare time I can scrounge up, which some months isn't much. :crying:
I have it completely re-assembled.
Fairings have been repaired and re-painted.
I fabricated a new windscreen from some material I found at work, and painted it to match the bike. Thinking I might cut it down further for a more interesting look, but still on the fence.
I designed a sequential LED circuit for the tail/blinkers. Still working out the details as far as mounting and such, but the end result will have the blinkers circling around each tail pod. Wanted to get the bodywork done before I got too crazy with the minor detailing. :smile:
I had to fabricate a new shifter mounting bracket as the original was damaged pretty bad.
Still need to replace the shift lever itself. Tis functional, but a little awkward as it stands.
The stator cover was cracked pretty bad, so replaced with a used one from our local salvage yard.
I re-covered the front seat because the original was in pretty sad shape. The back seat is better, but I think I will re-cover that as well, just so they match. :smile:
So... finally... I had it together enough to test! Fired up immediately, ran great except for the classic tensioner rattle. Rebuilt the tensioner and verified the timing. Now it runs great, sounds amazing. Toured my neighborhood with it a little, checking the ride, etc. Loving it. :grin2:
Then... went to start it again a couple days later and... nothing... :frown2:
Yep... the classic battery not charging syndrome...
Talked with the guy I bought it from and was informed that it had that problem before he bought it too. The previous owner replaced the stator and RR because it had the usual burned stator and fried connector.
The RR passes the meter tests, and the stator passes the ohm tests. Running the tests, the stator does not put out the correct AC voltage, in spite of looking brand new. Even the zip ties are still bright white!
At 5000 RPM, I get 34 volts on each set. Odd that all three are low, right? I usually see one set that is obviously bad when they fail.
Upon inspecting the rotor/flywheel, a couple of the magnet tabs are cracked (even tho primary magnets are layered behind the sleeve), and there is a noticeable gouge in the surface. Possibly from a previous crash? (the title does show prior salvage)
So... replaced the flywheel and still testing bad. :crying:
Since the original gentleman thought the bike was a 2000, I started thinking maybe he put the wrong parts in initially. There aren't any part numbers on the stator, but the micrometer measurements match what *should* be installed on a 99.
But the numbers are still no good. Next step will be to replace the stator with a known good one that is correct for this bike. That will have to wait for another paycheck or two though.
:gaah
Soooo close!! Getting antcy to get this thing on the road!
So all that remains is a set of mirrors and this charging issue resolved!!
Will update when I get the new parts installed!
-Troy